Optical component array

ABSTRACT

The present disclosure provides an optical component array and method of making an optical component array that can include a plurality of optical components useful for projection devices or other optical devices. The optical component array can be fabricated such that individual optical components having several elements can be assembled in a massively parallel manner and then singulated as individual optical components, and can result in a large reduction in manufacturing cost.

BACKGROUND

The operation of Liquid Crystal on Silicon (LCOS) based projectorsrequire the use of polarized light. Such projectors can require the useof polarizing beam splitters (PBS) and optionally, polarizationconverting systems (PCS) in order to operate efficiently. Thesespecialized optical components are typically assembled by hand. Becauseof this, the labor content of these devices is relatively high and theyield is relatively low. These two factors generally can lead to a highcost for the component. In addition, the hand assembly can limit the PBSto illumination applications. The high cost of the components is ironicbecause the LCOS imagers are relatively inexpensive, and LCOS basedsystems are purported to be low-cost systems. This can lead to thesituation where the high cost of the component offsets the low-cost ofthe imager.

SUMMARY

The present disclosure provides an optical component array and method ofmaking an optical component array that can include a plurality ofoptical components useful for projection devices or other opticaldevices. The optical component array can be fabricated such thatindividual optical components having several elements can be assembledin a massively parallel manner and then singulated as individual opticalcomponents, and can result in a large reduction in manufacturing cost.In one aspect, the present disclosure provides a polarizing beamsplitter(PBS) array that includes a reflective polarizer; a plurality of firstmachined prisms each having a first diagonal surface adhered to a majorsurface of the reflective polarizer; and a plurality of second machinedprisms each having a second diagonal surface adhered to an opposingmajor surface of the reflective polarizer. Each of the plurality of thefirst and the second machined prisms are aligned in registration withone another, forming a PBS array contiguous with the reflectivepolarizer.

In another aspect, the present disclosure provides an optical componentarray that includes a substrate film; a plurality of first machinedprismatic structures each having a first diagonal surface adhered to amajor surface of the substrate film; and a plurality of second machinedprismatic structures each having a second diagonal surface adhered to anopposing major surface of the substrate film. Each of the plurality ofthe first and the second machined prismatic structures are aligned inregistration with one another.

In yet another aspect, the present disclosure provides an opticalcomponent array that includes a substrate film; a plurality of firstmachined structures each having a first surface adhered to a majorsurface of the substrate film and a first land region connectingadjacent first machined structures; and a plurality of second machinedstructures each having a second surface adhered to an opposing majorsurface of the substrate film, and a second land region connectingadjacent second machined structures. Each of the plurality of the firstand the second machined structures are aligned such that at least aportion of the first land region and the second land region are alignedin registration to each other and separated by the substrate film.

In yet another aspect, the present disclosure provides a method ofmaking a PBS array that includes machining a first plurality of parallelvee-shaped ridges into a first sheet opposite a first planar surface,such that adjacent vee-shaped ridges are separated by a first landregion; machining a second plurality of parallel vee-shaped ridges intoa second sheet opposite a second planar surface, such that adjacentvee-shaped ridges are separated by a second land region; positioning asubstrate film between the first planar surface and the second planarsurface; aligning in registration the first plurality of parallelvee-shaped ridges with the second plurality of parallel vee-shapedridges; and adhering the substrate film between the first planar surfaceand the second planar surface.

In yet another aspect, the present disclosure provides a method ofmaking a PBS array that includes adhering a substrate film between afirst sheet and a second sheet; machining a first plurality of parallelvee-shaped ridges into the first sheet, such that adjacent vee-shapedridges are separated by a first land region; and machining a secondplurality of parallel vee-shaped ridges into the second sheet, such thatadjacent vee-shaped ridges are separated by a second land region andsuch that the first plurality of parallel vee-shaped ridges are alignedin registration with the second plurality of parallel vee-shaped ridges.

In yet another aspect, the present disclosure provides a method ofmaking an optical component array that includes machining at least twofirst grooves into a first sheet opposite a first planar surface, suchthat a first land region separates each first groove from the firstplanar surface; machining at least two second grooves into a secondsheet opposite a second planar surface, such that a second land regionseparates each second groove from the second planar surface; positioninga substrate film between the first planar surface and the second planarsurface; aligning in registration the at least two first grooves withthe at least two second grooves; and adhering the substrate film betweenthe first planar surface and the second planar surface.

In yet another aspect, the present disclosure provides a method ofmaking an optical component array that includes adhering a substratefilm between a first sheet and a second sheet; machining at least twofirst grooves into the first sheet, such that each of the at least twofirst grooves are separated from the substrate film by a first landregion; and machining at least two second grooves into the second sheet,such that each of the at least two second grooves are separated from thesheet by a second land region, and such that the first land region andsecond land region are aligned in registration opposite the substratefilm.

In yet another aspect, the present disclosure provides an opticalcomponent array that includes a planar optical stack; and a plurality offirst structures machined into the planar optical stack, each of theplurality of first structures having a first surface proximate to amajor surface of the planar optical stack and a first land regionconnecting adjacent first structures.

The above summary is not intended to describe each disclosed embodimentor every implementation of the present disclosure. The figures and thedetailed description below more particularly exemplify illustrativeembodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

Throughout the specification reference is made to the appended drawings,where like reference numerals designate like elements, and wherein:

FIGS. 1A-1E shows a perspective schematic view of steps of arepresentative technique to produce an optical component array;

FIG. 2A shows a cross-sectional schematic of an optical component;

FIG. 2B shows a cross-sectional schematic of an optical component;

FIGS. 3A-3F show a cross-sectional schematic view of a representativetechnique to produce an optical component array;

FIG. 4A shows a cross-sectional schematic view of a representativetechnique to produce an optical component monolith including a pluralityof optical component arrays; and

FIG. 4B shows a cross-sectional schematic view of a color combinersystem produced by the technique of FIG. 4A.

The figures are not necessarily to scale. Like numbers used in thefigures refer to like components. However, it will be understood thatthe use of a number to refer to a component in a given figure is notintended to limit the component in another figure labeled with the samenumber.

DETAILED DESCRIPTION

The present disclosure provides an optical component array and method ofmaking an optical component array that can include a plurality ofoptical components useful for projection devices or other opticaldevices. The optical component array can be fabricated such thatindividual optical components having several elements can be assembledin a massively parallel fashion and then singulated (i.e., separatedfrom each other) as individual optical components. This constructiontechnique opens the possibility for a large reduction in manufacturingcost, and can eliminate much of the hand assembly which can be asignificant source of variation in optical components. One obstacleencountered while manufacturing polarization control components is theneed to ensure that the components exhibit a low enough level ofbirefringence. This can be difficult to accomplish in the case ofmass-produced injection molded parts, since the residual stressassociated with injection molding may frequently lead to highbirefringence. However, at least for cost and lifetime reasons, plasticparts are very desirable.

In the following description, reference is made to the accompanyingdrawings that forms a part hereof and in which are shown by way ofillustration. It is to be understood that other embodiments arecontemplated and may be made without departing from the scope or spiritof the present disclosure. The following detailed description,therefore, is not to be taken in a limiting sense.

Unless otherwise indicated, all numbers expressing feature sizes,amounts, and physical properties used in the specification and claimsare to be understood as being modified in all instances by the term“about.” Accordingly, unless indicated to the contrary, the numericalparameters set forth in the foregoing specification and attached claimsare approximations that can vary depending upon the desired propertiessought to be obtained by those skilled in the art utilizing theteachings disclosed herein.

As used in this specification and the appended claims, the singularforms “a,” “an,” and “the” encompass embodiments having pluralreferents, unless the content clearly dictates otherwise. As used inthis specification and the appended claims, the term “or” is generallyemployed in its sense including “and/or” unless the content clearlydictates otherwise.

Spatially related terms, including but not limited to, “lower,” “upper,”“beneath,” “below,” “above,” and “on top,” if used herein, are utilizedfor ease of description to describe spatial relationships of anelement(s) to another. Such spatially related terms encompass differentorientations of the device in use or operation in addition to theparticular orientations depicted in the figures and described herein.For example, if an object depicted in the figures is turned over orflipped over, portions previously described as below or beneath otherelements would then be above those other elements.

As used herein, when an element, component or layer for example isdescribed as forming a “coincident interface” with, or being “on”“connected to,” “coupled with” or “in contact with” another element,component or layer, it can be directly on, directly connected to,directly coupled with, in direct contact with, or intervening elements,components or layers may be on, connected, coupled or in contact withthe particular element, component or layer, for example. When anelement, component or layer for example is referred to as being“directly on,” “directly connected to,” “directly coupled with,” or“directly in contact with” another element, there are no interveningelements, components or layers for example.

Also, for the purposes of the description provided herein, the term“aligned to a desired polarization state” is intended to associate thealignment of the pass axis of an optical element to a desiredpolarization state of light that passes through the optical element,i.e., a desired polarization state such as s-polarization,p-polarization, right-circular polarization, left-circular polarization,or the like. In one embodiment described herein with reference to theFigures, an optical element such as a polarizer aligned to the firstpolarization state means the orientation of the polarizer that passesthe p-polarization state of light, and reflects or absorbs the secondpolarization state (in this case the s-polarization state) of light. Itis to be understood that the polarizer can instead be aligned to passthe s-polarization state of light, and reflect or absorb thep-polarization state of light, if desired.

One factor that impacts the pocket projector market is the high cost ofthe projectors, especially if the projectors are battery powered. LCOSbased projectors have the potential of being low-cost because the imagercan be manufactured using the techniques of semiconductor manufacturing.Being based on polarization switching, these projectors requirepolarization control components such as polarizing beam splitters (PBS),polarization conversion systems (PCS), and conventional opticalcomponents such as color combiners (CC) and tapered light guides. Manyof these components are currently assembled by hand and can be quiteexpensive. The present disclosure provides a path to reduce the cost ofthese components by as much as an order of magnitude. Such a reductionin cost could make LCOS projectors the clear low-cost winner in thepocket projector marketplace.

In one aspect, the present disclosure provides a contiguous array ofoptical components and a technique for making them. This technique hasthe potential to dramatically reduce cost and waste, and also tosubstantially improve yield. In one particular embodiment, an array ofpolarizing beam splitters is fabricated through a machining approach, inwhich a two dimensional array of prism halves is machined out of asheet. A second array is also machined out of another sheet. In somecases, the second array can be an identical and symmetrical to the firstarray. The sheets are adhered together with a substrate film, such as anintermediate layer of optically functional material (such as a dichroiccoating, a multilayer optical film (MOF), a retarder, and the like)sandwiched between them. The resulting two dimensional array of opticalcomponents can then be used in aggregate, or rendered into individualoptical components through a singulating process.

In one particular embodiment a substrate film is laminated between thetwo sheets forming a “sandwich”, before machining the sheets. After thelamination step, the top side of the “sandwich” is milled to giveprismatic shaped rods. A special chuck is then built, and the secondside of the sandwich is milled. After that, crosscuts can be made tocreate individual PBSs. A thin layer of the sheet and the substrate filmcan continue to hold the individual PBSs together. In some embodiments,either at this point or before the crosscuts, the array of prisms can beantireflection (AR) coated. In some cases, the process can insteadinclude machining the sheets first and then laminating the substratefilm between the sheets after the machining has been completed. Thisapproach may give somewhat greater manufacturing flexibility.

In one particular embodiment, both the optical faces and the crosscutscan be milled in the sheet before the sheet is assembled into asandwich. A thin layer of material (e.g., a “land” region) remains atthe base of the sheet after machining and can serve to hold all of theprisms together so that they remain intact for further processing. Thisallows for the sheets to be glued to the substrate film, for example amultilayer optical film (MOF), cleanly and without overspill of theadhesive onto the sides of the prisms. In order to glue the sheet to theMOF, any effective technique may be used. In one particular embodiment,the MOF can be releasably attached onto a flat surface, and the requiredamount of adhesive placed on top of the MOF, whose extent may be largerthan the sheet. The sheet can then be placed on top of the pool ofadhesive causing the adhesive to flow out to the edges of the sheet. Theadhesive can then be cured or set (e.g., UV or thermal cured). Becauseof the thin layer of material connecting each of the prisms, the facesof the half prisms do not contact the adhesive. This can eliminate thetypical adhesive cleanup steps associated with manual assembly ofindividual prisms. In some cases, a pressure sensitive adhesive (PSA)can be applied to either the MOF or the machined prism sheet, and thenlaminated.

After the first sheet is adhered to the MOF, the sheet and the MOF canbe peeled away from the flat surface to which the MOF was releasablyattached. This construction can then be placed MOF side up and a secondquantity of adhesive can be placed on to the opposite side of the MOF.After this, the second sheet can be placed on top of the MOF, and againthe adhesive will flow out to the edges, and can then be cured.Alignment features can be provided in each of the sheets to permitreliable alignment of the prisms as the second sheet is adhered to theMOF/first sheet construction.

FIGS. 1A-1E show a perspective schematic view of steps of arepresentative technique to produce an optical component array,according to one aspect of the disclosure. In FIG. 1A, optical componentarray precursor 100 a can be a polarizing beam splitter (PBS) arrayprecursor 100 a that results in a PBS array as described throughout thefollowing description. PBS array precursor 100 a includes a first sheet110 a having a first major surface 112, and an opposing second majorsurface 114. A plurality of parallel vee-shaped ridges 116 that can bedescribed as “prism rods” are machined in the opposing second majorsurface 114, resulting in a series of first parallel grooves 118separating adjacent parallel vee-shaped ridges 116. It is to beunderstood that machined cross-sections other than vee-shaped ridges maybe used for other optical components; however, for the preparation ofPBS arrays, vee-shaped ridges can be preferred. An optional first frame115 can surround the first sheet 110 a to provide additional supportingstrength to the structure. A substrate 105 is adhered to the first majorsurface 112 of first sheet 110 a. In a similar manner, a second sheet120 a having a first major surface 122 and an opposing second majorsurface 124 can include similar machined structures, as describedelsewhere. The first major surface 122 of second sheet 120 a is alsoadhered to substrate 105, forming a laminate.

The first and second sheets 110 a, 120 a, can be any suitable polymer orglass that can be machined, such as visible-light transparent polymersand low birefringent glasses useful for optical components. In somecases, optical quality glass such as those available from Schott OpticalGlass, Duryea Pa. can be particularly useful. In one particularembodiment, polymers which can exhibit low birefringence including cellcast acrylic, polycarbonate, cyclo-olefin copolymers, and the like. Castacrylic polymers including Spartech Polycast® (available from SpartechCorp., Clayton, Mo.), Evonik Acrylite® GP (available from Evonik CyroLLC, Parsippany, N.Y.), Reynolds R-Cast™ (available from ReynoldsPolymer Technology, Grand Junction, Colo.) and Plexiglas® G (availablefrom Arkema Inc., Briston, Pa.). Cell cast acrylic polymers can bepreferred, since they can be readily machined providing a smoothsurface, minimal thermal effects from machining operations, and lowbirefringence. Although the disclosure that follows refers to the use ofpolymeric sheets (e.g., as the first and second polymeric sheets 110 a,120 a described below with reference to FIG. 1A), it is to be understoodthat glass sheets can instead be used to produce any of the opticalcomponent arrays described herein.

Substrate 105 can be any suitable substrate that can be affixed to,adhered to, or stably sandwiched between the first and second polymersheets 110 a, 120 a. In some cases, substrate 105 can be affixed oradhered over substantially the entire surface; however, in some casesonly a portion of the surface may be affixed or adhered. Substrate 105can serve a dual purpose. In some cases, substrate 105 can impart aphysical property such as strength to the optical component array suchthat machining operations can be reliably executed. In some cases,substrate 105 can be a portion of the optical component that imparts anoptical property such as polarization to the component. In oneparticular embodiment, substrate 105 can be a multilayer dielectric filmincluding inorganic films and coatings or multilayer film stacks;organic films such as polymeric films, polymeric film laminates, andmultilayer polymeric films including polarizers such as reflectivepolarizers and absorbing polarizers; polarizers including polymericmultilayer optical film polarizers, McNeill polarizers, and wire-gridpolarizers; retarders including quarter-wave retarders and half-waveretarders; films or coatings such as organic or inorganic dichroicreflectors and absorbers; and combinations thereof. In some cases,substrate 105 can be a coating or a layer that may be deposited bytechniques including a vapor deposition technique such as sputtering orchemical vapor deposition, or a liquid deposition technique such ascoating or spraying, onto one or both of the first and second polymericsheets 110 a, 120 a. In some cases, an adhesive can be used to adherethe first and second polymeric sheets 110 a, 120 a together, having thedeposited coating or layer between them.

In one particular embodiment, the substrate 105 is laminated between thefirst and second polymeric sheets 110 a, 120 a, before machining, forexample by using a suitably clear adhesive, such as an optical adhesive.In this embodiment, after the lamination step, the opposing second majorsurface 114 of the first polymeric sheet 110 a “sandwich” is milled togive the first plurality of vee-shaped ridges 116 (i.e., prism-shapedrods). A special chuck may then be used to secure the machinedstructure, and then the second side of the sandwich (i.e., the opposingsecond major surface 124 of the second polymeric sheet 120 a) is milled.

In one particular embodiment, the plurality of parallel vee-shapedridges 116 can instead be machined into first polymeric sheet 110 aprior to attaching the substrate 105 and the second polymeric sheet 120a. In this embodiment, either the second polymeric sheet 120 a can alsobe machined prior to attaching to the substrate 105 with attached firstpolymeric sheet 110 a, or the second polymeric sheet 120 a can bemachined after attaching to the substrate 105 with attached firstpolymeric sheet 110 a. In some cases, the substrate 105 can include aperimeter and an optional first frame 115 disposed adjacent theperimeter of the surface of the substrate 105, an optional second frame125 disposed adjacent the perimeter of the opposing surface of thesubstrate 105, and registration features (not shown) disposed andaligned within each of the optional first frame 115 and the optionalsecond frame 125. Optional first frame 115 can be integral with thefirst polymeric sheet 110 a, and optional second frame 125 can beintegral with the second polymeric sheet 120 a.

In FIG. 1B, PBS array precursor 100 b includes a first polymeric sheet110 b having a first major surface 112, a first plurality of parallelvee-shaped ridges 116 each having a first plurality of prism surfaces113, and a plurality of first parallel grooves 118 separating adjacentfirst parallel vee-shaped ridges 116. In FIG. 1B, optional first frame115 of FIG. 1A has been removed to more clearly show the fabrication ofthe PBS array from the PBS array precursor 100 b. An included firstprism angle θ1 in each of the parallel vee-shaped ridges 116 can be anydesired angle, depending on the optical component being fabricated. Inone particular embodiment, where a PBS array is being fabricated, theincluded first prism angle θ1 can be 90 degrees as shown in the figure.

A first polymeric land region 111 can connect adjacent first parallelvee-shaped ridges 116, for example to provide additional support andstrength to the PBS array precursor 100 b, and also to protect themachined surfaces from any adhesive applied during fabrication, asdescribed elsewhere. The first polymeric land region 111 may also serveto make the process of singulation into individual components lesscomplex. Substrate 105 is adhered to the first major surface 112 offirst polymeric sheet 110 b, and first polymeric land region 111separates the bottom of first parallel grooves 118 from the substrate105. The first polymeric land region 111 can have any desired thicknessand can extend for any desired distance between adjacent first parallelvee-shaped ridges 116. In some cases, the first polymeric land region111 can be a flat region parallel to the substrate and between theadjacent vee-shaped ridges 116.

In a similar manner, a second polymeric sheet 120 b having a first majorsurface 122 includes a second plurality of parallel vee-shaped ridges126 each having a second plurality of prism surfaces 123, and aplurality of second parallel grooves 128 separating adjacent secondparallel vee-shaped ridges 126. An included second prism angle θ2 ineach of the parallel vee-shaped ridges 126 can be any desired angle,depending on the optical component being fabricated. In one particularembodiment, where a PBS array is being fabricated, the included secondprism angle θ2 can be 90 degrees as shown in the figure.

As one of skill in the art would realize, it is to be understood thatthe first prism angle θ1 and/or the second prism angle θ2, can have anydesired orientation relative to the respective first major surfaces 112,122, depending on the optical component being fabricated. In some cases(not shown), for example, at least one of the first or second parallelvee-shaped ridges 116, 126, can have one or more of the first and/orsecond prism surface 113, 123 that is essentially perpendicular to therespective first major surface 112, 122. In this case, a correspondingadjacent prism surface of the first or second parallel vee-shaped ridges116, 126 disposed at the first prism angle θ1 and/or the second prismangle θ2 relative to the first and/or second prism surface 113, 123,resulting in a “saw tooth” type pattern of parallel vee-grooves.

A second polymeric land region 121 can connect adjacent second parallelvee-shaped ridges 126, for example to provide additional support andstrength to the PBS array precursor 100 b, and also to protect themachined surfaces from any adhesive applied during fabrication, asdescribed elsewhere. The second polymeric land region 121 may also serveto make the process of singulation into individual components lesscomplex. Substrate 105 is adhered to the first major surface 122 ofsecond polymeric sheet 120 b, and second polymeric land region 121separates the bottom of second parallel grooves 128 from the substrate105. The second polymeric land region 121 can have any desired thicknessand can extend for any desired distance between adjacent second parallelvee-shaped ridges 126. In some cases, the second polymeric land region121 can be a flat region parallel to the substrate and between theadjacent vee-shaped ridges 126. Each of the first and second pluralityof parallel vee-shaped ridges 116, 126 are aligned to be parallel toeach other and such that the first and second polymeric land regions111, 121, are immediately opposite the substrate from each other. Onehaving skill in the art will recognize that the placement of features(e.g., grooves and ridges) of the second polymeric sheet 120 b withrespect to features on the first polymeric sheet 110 b are determined bythe desired function of the component being constructed.

Each of the first plurality of prism surfaces 113 and the secondplurality of prism surfaces 123 are machined by techniques that mayprovide an acceptable surface finish that requires no additionalprocessing such as polishing prior to being used as an imaging PBS. Insome cases, the machining technique can be diamond machining including,for example, radial fly-cutting, axial fly-cutting, high speed diamondend milling, or diamond grinding. The surface finish can becharacterized by techniques including, for example, white lightinterferometry, stylus profilometry, confocal microscopy, or atomicforce microscopy (AFM). While it is generally accepted that a surfacehas “optical quality” if its finish is better than 3 micro-inches(approximately 75 nm) peak-to-valley measurement, each opticalapplication determines the actual acceptable requirement. In some cases,additional polishing can be performed if desired, including for examplepolishing using a technique comprising mechanical polishing, flamepolishing, vapor polishing, or a combination thereof.

In FIG. 1C, PBS array precursor 100 c shows the PBS array precursor 100b of FIG. 1B with additional features described below. Each of theelements 105-128 shown in FIG. 1C correspond to like-numbered elements105-128 shown in FIGS. 1A-1B, which have been described previously. Forexample, substrate 105 of FIG. 1C corresponds to substrate 105 of FIGS.1A-1B, and so on. PBS array precursor 100 c includes a first polymericsheet 110 c and second polymeric sheet 120 c. A first plurality ofparallel crosscuts 130 having a depth that leaves a first crosscut landregion 131 between the bottom of each parallel crosscut 130 andsubstrate 105, are made to be perpendicular to first plurality ofparallel vee-shaped ridges 116 in first polymeric sheet 110 c. Further,a second plurality of parallel crosscuts 140 having a depth that leavesa second crosscut land region 141 between the bottom of each parallelcrosscut 140 and substrate 105, are made to be perpendicular to secondplurality of parallel vee-shaped ridges 126 in second polymeric sheet120 c. Each of the first and second plurality of parallel crosscuts 130,140, can be made by any suitable technique including, for example,fly-cutting, laser ablating, sawing, milling, and the like. Further, itis to be understood that although the first and second plurality ofparallel crosscuts 130, 140, are shown as being perpendicular to therespective first and second parallel vee-shaped ridges 116, 126, thefirst and second plurality of parallel crosscuts 130, 140, could insteadbe made at any desired angle to them.

In FIG. 1D, PBS linear array precursor 100 d shows a portion of the PBSarray precursor 100 c of FIG. 1C with additional features describedbelow. Each of the elements 105-128 shown in FIG. 1D corresponds tolike-numbered elements 105-128 shown in FIGS. 1A-1C, which have beendescribed previously. For example, substrate 105 of FIG. 1D correspondsto substrate 105 of FIGS. 1A-1C, and so on. PBS linear array precursor100 d includes a first polymeric linear array 110 d and second polymericlinear array 120 d. Each of the first and second plurality of parallelcrosscuts 130, 140, as shown in FIG. 1C have been completed to seversubstrate 105 and first and second crosscut land regions 131, 141,leaving first polymeric linear array 110 d and second polymeric lineararray 120 d. Each of the completion cuts can be made by any suitabletechnique including, for example, fly-cutting, laser ablating, sawing,milling, and the like.

In FIG. 1E, singulated PBS array 100 e shows a portion of the PBS lineararray precursor 100 d of FIG. 1D with additional features describedbelow. Each of the elements 105-128 shown in FIG. 1E corresponds tolike-numbered elements 105-128 shown in FIGS. 1A-1D, which have beendescribed previously. For example, substrate 105 of FIG. 1E correspondsto substrate 105 of FIGS. 1A-1D, and so on. Singulated PBS array 100 eincludes a first through a fourth PBS 150 a-150 d that result when firstpolymeric linear array 110 d and second polymeric linear array 120 d aresingulated by severing substrate 105 and the first and second polymericland regions 111 and 121 located at the base of the plurality of firstparallel grooves 118. Each of the completion cuts can be made by anysuitable technique including, for example, fly-cutting, laser ablating,sawing, milling, and the like.

FIG. 2A shows a cross-sectional schematic of an optical component suchas a polarization conversion system (PCS) 200, according to one aspectof the disclosure. PCS 200 can be used to convert unpolarized light tolight of a single polarization state, as described below. PCS 200includes a first prism 210 having a first diagonal surface 215, an inputsurface 212, and an output surface 214; a second prism 220 having asecond diagonal surface 225, an output surface 222, and a side surface224; and a third prism 230 having a third diagonal surface 235, an inputsurface 232, and an output surface 234. A first reflective polarizer 240is disposed between the first and second prisms 210, 220, for example byuse of an optical adhesive between the first diagonal surface 215 andthe second diagonal surface 225. The first reflective polarizer 240 canbe aligned to a first polarization direction 295 such that onepolarization state (e.g., the p-polarization state) is transmittedthrough the first reflective polarizer 240 and an orthogonalpolarization state (e.g., the s-polarization state) is reflected fromthe first reflective polarizer 240.

In a similar manner, a second reflective polarizer 245 (or alternately asuitable broadband reflector) can be disposed on the third diagonalsurface 235 of the third prism 230, and a half-wave retarder 250 can bedisposed between the second prism 220 and the third prism 230. Each ofthe second reflective polarizer 245 and the half-wave retarder 250 canbe adhered to the respective component by use of an optical adhesive. Inone particular embodiment, the second reflective polarizer 245 can alsobe aligned to the first polarization direction 295, as describedelsewhere. In some cases, an optional protective coating 270 can beadhered to the second reflective polarizer 245, if desired.

In operation, an unpolarized light 260 enters the first prism 210 andintercepts first reflective polarizer 240 where it is split into atransmitted p-polarized light 261 and a reflected s-polarized light 262which exits the PCS 200. The transmitted p-polarized light 261 passesthrough second prism 220, rotates to transmitted s-polarized light 263as it passes through half-wave retarder 250, enters third prism 230,reflects from second reflective polarizer 245, and exits PCS 200 astransmitted s-polarized light 263.

The PCS 200 can be fabricated using traditional techniques, and entailshandling and proper alignment of several precise, small optical elementsincluding the individual first and second reflective polarizers 240,250, half-wave retarder 250, and first and second prisms 210, 220.Several steps are required to assemble the PCS 200, typically by hand,and since this traditional fabrication requires the use of an opticaladhesive to assemble the PCS, damage can often occur to the opticalelement.

FIG. 2B shows a cross-sectional schematic of an optical component suchas a polarization conversion system (PCS) 201, according to one aspectof the disclosure. PCS 201 can be used to convert unpolarized light tolight of a single polarization state, in a manner similar to thatdescribed for PCS 200 in FIG. 2A. Each of the elements 210-295 shown inFIG. 2B corresponds to like-numbered elements 210-295 shown in FIG. 2A,which have been described previously. For example, first prism 210 ofFIG. 2B corresponds to first prism 210 of FIG. 2A, and so on.

PCS 201 includes a first prism 210 having a first diagonal surface 215,an input surface 212, and an output surface 214; a rhombus 221 having asecond diagonal surface 226, a side surface 224, an output surface 234,and a third diagonal surface 236. A reflective polarizer laminate 255 isdisposed between the first diagonal surface 215 of the first prism 210and the second diagonal surface 226 of the rhombus 221. The reflectivepolarizer laminate 255 includes a first reflective polarizer 240 and ahalf-wave retarder 250, and the reflective polarizer laminate 255 ispositioned such that the first reflective polarizer 240 is immediatelyadjacent the first diagonal surface 215. Each of the layers of thereflective polarizer laminate 255 can be adhered to their respectiveadjacent optical elements, by use of an optical adhesive. The firstreflective polarizer 240 can be aligned to a first polarizationdirection 295 such that one polarization state (e.g., the p-polarizationstate) is transmitted through the first reflective polarizer 240 and anorthogonal polarization state (e.g., the s-polarization state) isreflected from the first reflective polarizer 240.

In a similar manner, a second reflective polarizer 245 (or alternately asuitable broadband reflector) can be disposed on the third diagonalsurface 236 of the rhombus 221. The second reflective polarizer 245 canbe adhered to the third diagonal surface 236 by use of an opticaladhesive. In one particular embodiment, the second reflective polarizer245 can also be aligned to the first polarization direction 295, asdescribed elsewhere. In some cases, an optional protective coating 270can be adhered to the second reflective polarizer 245, if desired. It isto be noted that the rhombus 221 of FIG. 2B corresponds to a combinationof the second prism 220 and third prism 230 shown in FIG. 2A, withre-positioning of the half-wave retarder 250.

In operation, an unpolarized light 260 enters the first prism 210 andintercepts first reflective polarizer 240 where it is split into areflected s-polarized light 262 and a transmitted p-polarized light thatpasses through the half-wave retarder 250 becoming a transmitteds-polarized light 263. The reflected s-polarized light 262 exits the PCS201. The transmitted s-polarized light 263 passes through rhombus 221,reflects from second reflective polarizer 245, and exits PCS 200 astransmitted s-polarized light 263. The PCS 201 can be fabricated usingthe optical component array technique described herein, and eliminatesmany of the problems described above regarding traditional assemblytechniques.

In one particular embodiment, the fabrication of any optical componentarray can begin with a planar optical stack that comprises an adhesive,a plastic such as a visible-light transparent plastic, a glass, adichroic coating, a scattering material, a reflective polarizer, anabsorbing polarizer, a multilayer optical film, a retarder, a reflector,a retro reflector, a microstructured material, a lenticular structuredmaterial, a Fresnel structured material, an absorber, or a combinationthereof. The planar optical stack can be arranged as needed to producethe desired optical component, and then be subject to the machiningsteps described herein. It is to be understood that the fabrication ofan array of optical components can include combining the result ofseveral array fabrication steps, such as lamination of a first array of3-dimensional structures to a second array of 3-dimensional structures.In some cases, such a combination can include combining a firstsingulated element, linear array, or rectangular array of a firstcomponent with a second singulated element, linear array, or rectangulararray of a second component. Included below is a representativefabrication technique for an optical component array of PCS components,which includes a combination of linear or rectangular arrays ofcomponents to form a monolithic array of components that can besingulated to result in individual PCS components.

FIGS. 3A-3F show a cross-sectional schematic view of a representativetechnique to produce an optical component array, such as an array of PCScomponents useful in projection displays, according to one aspect of thedisclosure. FIG. 3A shows a PCS precursor laminate 300 a that includes afirst acrylic sheet 310 having a first major surface 314 and a secondmajor surface 316. A first substrate 315 is laminated to the secondmajor surface 316 of the first acrylic sheet 310, for example using anoptical adhesive. First substrate 315 can be a laminate of a reflectivepolarizer 315 a and a half-wave retarder 315 b disposed so that thereflective polarizer 315 a is immediately adjacent second major surface316 of first acrylic sheet 310. The reflective polarizer 315 a isaligned to a first polarization direction 395, thereby transmittingfirst polarization direction 395 and reflecting an orthogonal secondpolarization of light. The half-wave retarder 315 b is aligned toefficiently rotate the transmitted first polarization direction light395 to the orthogonal second polarization direction light.

A second acrylic sheet 320 having a first major surface 324 and a secondmajor surface 326 is adhered, for example using an optical adhesive, tothe first substrate 315 such that the first major surface 324 andhalf-wave retarder 315 b are adjacent each other. A second reflectivepolarizer 325 aligned to the first polarization direction 395, isadhered using an optical adhesive to the second major surface 326 of thesecond acrylic sheet 320. Those of skill in the art would understandthat the second reflective polarizer 325 may also be a reflector, suchas a simple broadband reflector, since only reflection and not anypolarization discrimination takes place from second reflective polarizer325. A third acrylic sheet 330 having a first major surface 334 and asecond major surface 336 is then disposed on the second reflectivepolarizer 325 such that the first major surface 334 is adjacent thesecond reflective polarizer 325. The third acrylic sheet 330 can also belaminated using an optical adhesive.

In FIG. 3B, a PCS precursor laminate 300 b can be held in place securelyusing a vacuum chuck (not shown) or other suitable hold-down deviceaffixed to first major surface 314 of first acrylic sheet 310. Aplurality of first vee-grooves 340 are then milled through third acrylicsheet 330, second reflective polarizer 325, and second acrylic sheet320, as described elsewhere. Each of the plurality of first vee-grooves340 includes two sides that can be correlated with side surface 224 ofPCS 201 as shown in FIG. 2B. At the bottom of each of the plurality offirst vee-grooves 340, a land region (not shown) may remain to addstrength to the structure, as described elsewhere.

In FIG. 3C, a PCS precursor laminate 300 c is the PCS precursor laminate300 b of FIG. 3B flipped over, and a vacuum chuck or other suitablehold-down device (not shown) is affixed to second major surface 336 ofthird acrylic sheet 330, or a similar hold-down device is applied tosecure the PCS precursor laminate 300 c.

In FIG. 3D, a PCS precursor laminate 300 d includes a plurality ofsecond vee-grooves 350 which are then milled through first acrylic sheet310, first substrate 315, and second acrylic sheet 320, as describedelsewhere and shown in FIG. 3D. Each of the plurality of secondvee-grooves 350 includes two sides that can be correlated with outputsurfaces 214 and 234 of PCS 201 as shown in FIG. 2B. At the bottom ofeach of the plurality of second vee-grooves 350, a land region (notshown) may remain to add strength to the structure, as describedelsewhere.

In FIG. 3E, a PCS precursor laminate 300 e includes a plurality of thirdvee-grooves 360 which are then milled through first acrylic sheet 310,as described elsewhere and shown in FIG. 3E. Each of the plurality ofthird vee-grooves 360 includes two sides that can be correlated withinput surface 212 of PCS 201 as shown in FIG. 2B. At the bottom of eachof the plurality of third vee-grooves 360, a land region (not shown) mayremain to add strength to the structure, as described elsewhere.

In FIG. 3F, a singulated PCS array 300 f includes a plurality ofindividual PCS optical components 370 a-370 h that result when the PCSprecursor laminate 300 e of FIG. 3E is singulated by any of thetechniques described elsewhere. Each of the individual PCS opticalcomponents 370 a-370 h can be compared to the PCS 201 of FIG. 2B.

FIG. 4A shows a cross-sectional schematic view of a representativetechnique to produce an optical component monolith 400 including aplurality of optical component arrays, according to one aspect of thedisclosure. In one particular embodiment, optical component monolith 400can be used to produce a plurality of tilted dichroic color combinerswith a polarization conversion feature, as described below, and includesseveral optical component linear arrays similar to the PBS linear arrayprecursor 100 d shown in FIG. 1D. It is to be understood that althoughthe description provided below is specific to producing a three colorcombiner having a polarized white light output, any desired modificationcan be made to the various components and component orientation toproduce any desired optical component, as known to one of skill in theart.

It is to be understood that the description that follows is directed toassembling a plurality of optical component linear arrays similar to thePBS linear array precursors 100 d into a monolith 400 and separating theindividual PCS optical components from the monolith by cutting asdescribed elsewhere. However, the monolith 400 can instead be formedusing several alternative optical component arrays. In one particularembodiment, a plurality of optical component arrays similar to the PBSarray precursor 100 c shown in FIG. 1C can instead be assembled bystacking and adhering into a first array monolith (not shown). In oneparticular embodiment, a plurality of optical component arrays similarto the PBS array precursor 100 b shown in FIG. 1B can instead beassembled by stacking and adhering into a second array monolith (notshown). In these embodiments, the assembled first or second arraymonoliths can be separated using any of the cutting, sawing, or millingtechniques described herein, and one of skill in the art would realizethat the PCS optical component can be singulated by performing a firstseries of cuts to separate the respective first or second array monolithinto the monolith 400 assembled from the linear array precursors, andsecond cuts as described below. Generally, each of the arrays can beadhered together using a suitable optical adhesive that can be infusedbetween the stacked precursor arrays using a known technique similar tothat used to fill a liquid crystal display with LCD material.

Optical component monolith 400 includes a first optical component lineararray 400 a, a second optical component linear array 400 b, a thirdoptical component linear array 400 c, a fourth optical component lineararray 400 d, and a fifth optical component linear array 400 e. Each ofthe first through fifth optical component linear arrays 400 a-400 e arenested together as shown in FIG. 4A, such that a ridge 416 and a groove418 adjacent each other can be affixed together with an adhesive 406disposed between them. In one particular embodiment shown in FIG. 4A,the peaks of each ridge 416 can be shaped such that the ridge 416 andgroove 418 can be closely nested together when the optical componentmonolith 400 is compressed and adhered together. It is to be understoodthat one skilled in the art may choose an adhesive having a refractiveindex suitable for controlling the level of total internal reflection,thereby maximizing the efficiency of the component.

First optical component linear array 400 a includes a first polymericlinear array 410 a and a second polymeric linear array 420 a with a reddichroic mirror film 405 a disposed between them. First opticalcomponent linear array 400 a can be produced in the manner describedwith reference to FIGS. 1A-1D by substituting the red dichroic mirrorfilm 405 a for the substrate 105, as described elsewhere.

Second optical component linear array 400 b includes a third polymericlinear array 410 b and a fourth polymeric linear array 420 b with agreen dichroic mirror film 405 b disposed between them. Second opticalcomponent linear array 400 b can be produced in the manner describedwith reference to FIGS. 1A-1D by substituting the green dichroic mirrorfilm 405 b for the substrate 105, as described elsewhere.

Third optical component linear array 400 c includes a fifth polymericlinear array 410 c and a sixth polymeric linear array 420 c with a bluedichroic mirror film 405 c disposed between them. Third opticalcomponent linear array 400 c can be produced in the manner describedwith reference to FIGS. 1A-1D by substituting the blue dichroic mirrorfilm 405 c for the substrate 105, as described elsewhere.

Fourth optical component linear array 400 d includes a seventh polymericlinear array 410 d and an eighth polymeric linear array 420 d with areflective polarizer film laminate 405 d disposed between them. In oneparticular embodiment, reflective polarizer film laminate 405 d includesa reflective polarizer film laminated to a retarder such as a half-waveretarder. In the reflective polarizer film laminate 405, the reflectivepolarizer film can be aligned, for example, such that incidentp-polarized light is reflected, and s-polarized light is transmittedthrough the half-wave retarder and converted to p-polarized light.Fourth optical component linear array 400 d can be produced in themanner described with reference to FIGS. 1A-1D by substituting thereflective polarizer film laminate 405 d for the substrate 105, asdescribed elsewhere.

Fifth optical component linear array 400 e includes a ninth polymericlinear array 410 e and a tenth polymeric linear array 420 e with areflective polarizer film 405 e disposed between them. In one particularembodiment, the reflective polarizer film can be aligned such thatincident p-polarized light is reflected, and s-polarized film istransmitted. Fifth optical component linear array 400 e can be producedin the manner described with reference to FIGS. 1A-1D by substitutingthe reflective polarizer film 405 e for the substrate 105, as describedelsewhere.

The optical component monolith 400 can then be cut with a first cut 430and a second cut 440 such that a first through a tenth prism, 450-459,become a color combiner/polarization converter 460 separated from theremainder of the optical component monolith 400. Each of the first andsecond cuts 430, 440, can be made by any suitable technique including,for example, fly-cutting, laser ablating, sawing, milling, and the like,and if required, each surface the color combiner 460 can be polished, asknown to one of skill in the art.

FIG. 4B shows a cross-sectional schematic view of a colorcombiner/polarization converter system 401 produced by the technique ofFIG. 4A. Color combiner/polarization converter system 401 includes thecolor combiner/polarization converter 460 described with reference toFIG. 4A and a first, a second, and a third light emitting diode (LED).First LED 470 injects an unpolarized red light 471 into second prism 451where it reflects from red dichroic mirror film 405 a, passes unchangedthrough green dichroic mirror film 405 b and blue dichroic mirror film405 c, and intercepts reflective polarizer laminate 405 d where it issplit into a reflected p-polarized red light 472 and transmittedp-polarized red light 473, as described elsewhere. Reflected p-polarizedred light 472 exits color combiner 460 through seventh prism 456.Transmitted p-polarized red light 473 reflects from reflective polarizerfilm 405 e and exits color combiner 460 through ninth prism 458.

Second LED 480 injects an unpolarized green light 481 into fourth prism453 where it reflects from green dichroic mirror film 405 b, passesunchanged through blue dichroic mirror film 405 c, and interceptsreflective polarizer laminate 405 d where it is split into a reflectedp-polarized green light 482 and transmitted p-polarized green light 483,as described elsewhere. Reflected p-polarized green light 482 exitscolor combiner 460 through seventh prism 456. Transmitted p-polarizedgreen light 483 reflects from reflective polarizer film 405 e and exitscolor combiner 460 through ninth prism 458.

Third LED 490 injects an unpolarized blue light 491 into sixth prism 455where it reflects from blue dichroic mirror film 405 c, and interceptsreflective polarizer laminate 405 d where it is split into a reflectedp-polarized blue light 492 and transmitted p-polarized blue light 493,as described elsewhere. Reflected p-polarized blue light 492 exits colorcombiner 460 through seventh prism 456. Transmitted p-polarized bluelight 493 reflects from reflective polarizer film 405 e and exits colorcombiner/polarization converter 460 through ninth prism 458. Thecombination of reflected and transmitted p-polarized red, green, andblue light (472, 473, 482, 483, 492, 493) collectively combine to becomep-polarized white light 495.

Example

An optical component array was fabricated. In the first fabricationstep, prism rods having an included angle of 90 degrees were machinedinto a cell cast acrylic sheet 0.5 inches (1.27 cm) thick, (availablefrom McMaster-Carr, Princeton, N.J.), leaving a 0.15 mm thick and 3 minwide land region between adjacent prism rods. After the milling process,a Vikuiti™ MOF reflective polarizer, available from 3M Company, wasreleasably disposed onto a sacrificial acrylic flat. A suitable quantityof Norland 75 UV Optical Adhesive (available from Norland Products,Cranbury N.J.) was deposited onto the MOF in a quantity sufficient tocreate a 100-200 μm layer across the entire extent of the milled sheet.The milled sheet was placed on top of the adhesive and the adhesive wasallowed to flow out. The adhesive was then cured according to themanufacturer's instructions. The milled sheet with MOF adhered was thenremoved from the sacrificial flat. The removed MOF retained its flatnessfrom its original disposition onto the sacrificial flat. The milledsheet/MOF construction was then turned MOF side up. A second quantity ofadhesive was applied to the MOF surface and the second milled sheet wasapplied as before. Dowel pins were inserted into registration holes toproperly align the two sheets. The adhesive was cured as before and thearray of PBSs was complete. The array of PBSs were singulated intoindividual PBSs by breaking the individual PBSs loose and cutting theconnecting film with a razor blade. The prism rods could also becrosscut using a suitable saw such as an optical saw with a diamondblade, or milled, or laser cut, without significant damage to the prismfaces such as chipping or melting. The optical surfaces of the prismswere sufficiently good to minimize any reduction in resolution, and werejudged to be suitably good for a projection application.

Following are a list of embodiments of the present disclosure.

Item 1 is a polarizing beamsplitter (PBS) array, comprising: areflective polarizer; a plurality of first machined prisms each having afirst diagonal surface adhered to a major surface of the reflectivepolarizer; and a plurality of second machined prisms each having asecond diagonal surface adhered to an opposing major surface of thereflective polarizer, wherein each of the plurality of the first and thesecond machined prisms are aligned in registration with one another,forming a PBS array contiguous with the reflective polarizer.

Item 2 is the PBS array of item 1, wherein a first land region connectsadjacent first machined prisms, and a second land region connectsadjacent second machined prisms.

Item 3 is the PBS array of item 1 or item 2, wherein the first machinedprisms and the second machined prisms each comprise a low-birefringentmaterial.

Item 4 is the PBS array of item 3, wherein the low-birefringent materialcomprises an acrylic polymer, a polycarbonate polymer, a cyclo-olefincopolymer, or a glass.

Item 5 is the PBS array of item 4, wherein the acrylic polymer is a castacrylic polymer.

Item 6 is the PBS array of item 1 to item 5, wherein the reflectivepolarizer comprises a polymeric multilayer optical film polarizer, aMcNeill polarizer, or a wire-grid polarizer.

Item 7 is the PBS array of item 1 to item 6, wherein the plurality offirst machined prisms and the plurality of second machined prisms eachform a rectangular shaped array.

Item 8 is the PBS array of item 1 to item 7, wherein the machined prismsare polished using a technique comprising mechanical polishing, flamepolishing, vapor polishing, or a combination thereof.

Item 9 is the PBS array of item 1 to item 8, wherein the reflectivepolarizer comprises a perimeter, and further comprising: a first framedisposed adjacent the perimeter of the major surface of the reflectivepolarizer, a second frame disposed adjacent the perimeter of theopposing major surface of the reflective polarizer, and registrationfeatures disposed and aligned within each of the first frame and thesecond frame.

Item 10 is an optical component array, comprising: a substrate film; aplurality of first machined prismatic structures each having a firstprism surface adhered to a major surface of the substrate film; and aplurality of second machined prismatic structures each having a secondprism surface adhered to an opposing major surface of the substratefilm, wherein each of the plurality of the first and the second machinedprismatic structures are aligned in registration with one another.

Item 11 is the optical component array of item 10, wherein opposingpairs of first and second machined prismatic structures form rectangularprismatic optical elements.

Item 12 is the optical component array of item 10 or item 11, wherein afirst land region connects adjacent first machined prismatic structures,and a second land region connects adjacent second machined prismaticstructures.

Item 13 is the optical component array of item 10 to item 12, whereinthe first machined prismatic structures and the second machinedprismatic structures each comprise a low-birefringent material.

Item 14 is the optical component array of item 13, wherein thelow-birefringent material comprises an acrylic polymer, a polycarbonatepolymer, or a cycloolefin copolymer.

Item 15 is the optical component array of item 14, wherein the acrylicpolymer is cast acrylic.

Item 16 is the optical component array of item 10 to item 15, whereinthe substrate film comprises an adhesive, a transparent plastic, aglass, a dichroic coating, a scattering material, a reflectivepolarizer, an absorbing polarizer, a multilayer optical film, aretarder, a reflector, a retro reflector, a microstructured material, alenticular structured material, a fresnel structured material, anabsorber, or a combination thereof.

Item 17 is the optical component array of item 10 to item 16, whereinthe substrate film comprises a film laminate.

Item 18 is the optical component array of item 17, wherein the filmlaminate comprises at least two films selected from a multilayerdielectric film including inorganic films and coatings or multilayerfilm stacks; organic films such as polymeric films, polymeric filmlaminates, and multilayer polymeric films including polarizers such asreflective polarizers and absorbing polarizers; polarizers includingpolymeric multilayer optical film polarizers, McNeill polarizers, andwire-grid polarizers; retarders including quarter-wave retarders andhalf-wave retarders; and films or coatings such as organic or inorganicdichroic reflectors and absorbers.

Item 19 is the optical component array of item 10 to item 18, whereinthe plurality of first machined prismatic structures and the pluralityof second machined prismatic structures each form a rectangular shapedarray.

Item 20 is the optical component array of item 10 to item 19, whereinthe substrate film comprises a perimeter, and further comprising: afirst frame disposed adjacent the perimeter of the major surface of thesubstrate film, a second frame disposed adjacent the perimeter of theopposing major surface of the substrate film, and registration featuresdisposed and aligned within each of the first frame and the secondframe.

Item 21 is an optical component array, comprising: a substrate film; aplurality of first machined structures each having a first surfaceadhered to a major surface of the substrate film and a first land regionconnecting adjacent first machined structures; and a plurality of secondmachined structures each having a second surface adhered to an opposingmajor surface of the substrate film, and a second land region connectingadjacent second machined structures, wherein each of the plurality ofthe first and the second machined structures are aligned such that atleast a portion of the first land region and the second land region arealigned in registration to each other and separated by the substratefilm.

Item 22 is the optical component array of item 21, wherein the firstmachined structures and the second machined structures each comprise alow-birefringent material.

Item 23 is the optical component array of item 22, wherein thelow-birefringent material comprises an acrylic polymer, a polycarbonatepolymer, a cyclo-olefin copolymer, or a glass.

Item 24 is the optical component array of item 23, wherein the acrylicpolymer is cast acrylic.

Item 25 is the optical component array of item 21 to item 24, whereinthe substrate film comprises an adhesive, a transparent plastic, aglass, a dichroic coating, a scattering material, a reflectivepolarizer, an absorbing polarizer, a multilayer optical film, aretarder, a reflector, a retro reflector, a microstructured material, alenticular structured material, a fresnel structured material, anabsorber, or a combination thereof.

Item 26 is the optical component array of item 21 to item 25, whereinthe substrate film comprises a film laminate.

Item 27 is the optical component array of item 26, wherein the filmlaminate comprises comprises at least two films selected from amultilayer dielectric film including inorganic films and coatings ormultilayer film stacks; organic films such as polymeric films, polymericfilm laminates, and multilayer polymeric films including polarizers suchas reflective polarizers and absorbing polarizers; polarizers includingpolymeric multilayer optical film polarizers, McNeill polarizers, andwire-grid polarizers; retarders including quarter-wave retarders andhalf-wave retarders; and films or coatings such as organic or inorganicdichroic reflectors and absorbers.

Item 28 is the optical component array of item 21 to item 27, whereinthe plurality of first machined structures and the plurality of secondmachined structures each form a rectangular array.

Item 29 is the optical component array of item 21 to item 24, whereinthe substrate film comprises a perimeter, and further comprising: afirst frame disposed adjacent the perimeter of the major surface of thesubstrate film, a second frame disposed adjacent the perimeter of theopposing major surface of the substrate film, and registration featuresdisposed and aligned within each of the first frame and the secondframe.

Item 30 is a method of making a PBS array, comprising: machining a firstplurality of parallel vee-shaped ridges into a first sheet opposite afirst planar surface, such that adjacent vee-shaped ridges are separatedby a first land region; machining a second plurality of parallelvee-shaped ridges into a second sheet opposite a second planar surface,such that adjacent vee-shaped ridges are separated by a second landregion; positioning a substrate film between the first planar surfaceand the second planar surface; aligning in registration the firstplurality of parallel vee-shaped ridges with the second plurality ofparallel vee-shaped ridges; and adhering the substrate film between thefirst planar surface and the second planar surface.

Item 31 is a method of making a PBS array, comprising: adhering asubstrate film between a first sheet and a second sheet; machining afirst plurality of parallel vee-shaped ridges into the first sheet, suchthat adjacent vee-shaped ridges are separated by a first land region;and machining a second plurality of parallel vee-shaped ridges into thesecond sheet, such that adjacent vee-shaped ridges are separated by asecond land region and such that the first plurality of parallelvee-shaped ridges are aligned in registration with the second pluralityof parallel vee-shaped ridges.

Item 32 is the method of item 30 or item 31, further comprisingmachining crosscuts into at least one of the first and second sheets atan angle to the first plurality of parallel vee-shaped ridges and thesecond plurality of parallel vee-shaped ridges.

Item 33 is the method of item 32, wherein the crosscuts areperpendicular to the first plurality of parallel vee-shaped ridges andthe second plurality of parallel vee-shaped ridges

Item 34 is a method of making an optical component array, comprising:machining at least two first grooves into a first sheet opposite a firstplanar surface, such that a first land region separates each firstgroove from the first planar surface; machining at least two secondgrooves into a second sheet opposite a second planar surface, such thata second land region separates each second groove from the second planarsurface; positioning a substrate film between the first planar surfaceand the second planar surface; aligning in registration the at least twofirst grooves with the at least two second grooves; and adhering thesubstrate film between the first planar surface and the second planarsurface.

Item 35 is a method of making an optical component array, comprising:adhering a substrate film between a first sheet and a second sheet;machining at least two first grooves into the first sheet, such thateach of the at least two first grooves are separated from the substratefilm by a first land region; and machining at least two second groovesinto the second sheet, such that each of the at least two second groovesare separated from the sheet by a second land region, and such that thefirst land region and second land region are aligned in registrationopposite the substrate film.

Item 36 is the method of any of item 30 to item 35, further comprisingmachining crosscuts perpendicular to the first and second land regions.

Item 37 is the method of any of item 30 to item 36, wherein machiningcomprises milling and fly-cutting.

Item 38 is the method of item 36 or item 37, further comprisingmachining crosscuts into at least one of the first and second sheets atan angle to the at least two first grooves and the at least two secondgrooves.

Item 39 is the method of item 37, wherein the crosscuts areperpendicular to the at least two first grooves and the at least twosecond grooves.

Item 40 is the method of any of item 30 to item 39, wherein machiningcomprises milling and fly-cutting.

Item 41 is the method of any of item 30 to item 40, wherein thesubstrate film comprises an adhesive, a transparent plastic, a glass, adichroic coating, a scattering material, a reflective polarizer, anabsorbing polarizer, a multilayer optical film, a retarder, a reflector,a retro reflector, a microstructured material, a lenticular structuredmaterial, a fresnel structured material, an absorber, or a combinationthereof.

Item 42 is the method of any of items 30 to item 41, further comprisingsingulating the optical component array by severing substrate film, thefirst land region, and the second land region by laser cutting, sawing,milling, fly-cutting, or a combination thereof.

Item 43 is an optical component array, comprising: a planar opticalstack; and a plurality of first structures machined into the planaroptical stack, each of the plurality of first structures having a firstsurface proximate to a major surface of the planar optical stack and afirst land region connecting adjacent first structures.

Item 44 is the optical component array of item 43, further comprising aplurality of second machined structures each having a second surfaceproximate to an opposing major surface of the planar optical stack, anda second land region connecting adjacent second machined structures,wherein each of the plurality of the first and the second machinedstructures are aligned in registration to form an array of substantiallyidentical optical components.

Item 45 is the optical component array of item 43 or item 44, whereinthe planar optical stack comprises an adhesive, a transparent plastic, aglass, a dichroic coating, a scattering material, a reflectivepolarizer, an absorbing polarizer, a multilayer optical film, aretarder, a reflector, a retro reflector, a microstructured material, alenticular structured material, a fresnel structured material, anabsorber, or a combination thereof.

Unless otherwise indicated, all numbers expressing feature sizes,amounts, and physical properties used in the specification and claimsare to be understood as being modified by the term “about”. Accordingly,unless indicated to the contrary, the numerical parameters set forth inthe foregoing specification and attached claims are approximations thatcan vary depending upon the desired properties sought to be obtained bythose skilled in the art utilizing the teachings disclosed herein.

All references and publications cited herein are expressly incorporatedherein by reference in their entirety into this disclosure, except tothe extent they may directly contradict this disclosure. Althoughspecific embodiments have been illustrated and described herein, it willbe appreciated by those of ordinary skill in the art that a variety ofalternate and/or equivalent implementations can be substituted for thespecific embodiments shown and described without departing from thescope of the present disclosure. This application is intended to coverany adaptations or variations of the specific embodiments discussedherein. Therefore, it is intended that this disclosure be limited onlyby the claims and the equivalents thereof.

What is claimed is:
 1. An optical component array, comprising: asubstrate film; a plurality of first machined prismatic structuresspaced apart by substantially flat first land regions parallel to thereflective polarizer, each first machined prismatic structure having afirst diagonal surface adhered to a major surface of the substrate film;and a plurality of second machined prismatic structures spaced apart bysubstantially flat second land regions parallel to the reflectivepolarizer, each second machined prismatic structure having a seconddiagonal surface adhered to an opposing major surface of the substratefilm, wherein each of the plurality of the first and the second machinedprismatic structures are aligned in registration with one another. 2.The optical component array of claim 1, wherein opposing pairs of firstand second machined prismatic structures form rectangular prismaticoptical elements.
 3. The optical component array of claim 1, wherein theplurality of first machined prismatic structures and the plurality ofsecond machined prismatic structures each form a rectangular shapedarray.
 4. The optical component array of claim 1, wherein the firstmachined prismatic structures and the second machined prismaticstructures each comprise a low-birefringent material.
 5. The opticalcomponent array of claim 4, wherein the low-birefringent materialcomprises an acrylic polymer, a polycarbonate polymer, or a cycloolefincopolymer.
 6. The optical component array of claim 5, wherein theacrylic polymer is cast acrylic.
 7. The optical component array of claim1, wherein the substrate film comprises an adhesive, a transparentplastic, a glass, a dichroic coating, a scattering material, areflective polarizer, an absorbing polarizer, a multilayer optical film,a retarder, a reflector, a retro reflector, a microstructured material,a lenticular structured material, a fresnel structured material, anabsorber, or a combination thereof.
 8. The optical component array ofclaim 1, wherein the substrate film comprises a film laminate.
 9. Theoptical component array of claim 8, wherein the film laminate comprisesat least two films selected from a multilayer dielectric film includinginorganic films and coatings or multilayer film stacks; organic filmssuch as polymeric films, polymeric film laminates, and multilayerpolymeric films including polarizers such as reflective polarizers andabsorbing polarizers; polarizers including polymeric multilayer opticalfilm polarizers, McNeill polarizers, and wire-grid polarizers; retardersincluding quarter-wave retarders and half-wave retarders; and films orcoatings such as organic or inorganic dichroic reflectors and absorbers.10. The optical component array of claim 1, wherein the substrate filmcomprises a perimeter, and further comprising: a first frame disposedadjacent the perimeter of the major surface of the substrate film, asecond frame disposed adjacent the perimeter of the opposing majorsurface of the substrate film, and registration features disposed andaligned within each of the first frame and the second frame.
 11. Anoptical component array, comprising: a substrate film; a plurality offirst machined structures each having a first surface adhered to a majorsurface of the substrate film and a substantially flat first land regionparallel to the substrate film connecting adjacent first machinedstructures; and a plurality of second machined structures each having asecond surface adhered to an opposing major surface of the substratefilm, and a substantially flat second land region parallel to thesubstrate film connecting adjacent second machined structures, whereineach of the plurality of the first and the second machined structuresare aligned such that at least a portion of the first land region andthe second land region are aligned in registration to each other andseparated by the substrate film.
 12. The optical component array ofclaim 11, wherein the plurality of first machined structures and theplurality of second machined structures each form a rectangular array.13. The optical component array of claim 11, wherein the first machinedstructures and the second machined structures each comprise alow-birefringent material.
 14. The optical component array of claim 13,wherein the low-birefringent material comprises an acrylic polymer, apolycarbonate polymer, a cyclo-olefin copolymer, or a glass.
 15. Theoptical component array of claim 14, wherein the acrylic polymer is castacrylic.
 16. The optical component array of claim 11, wherein thesubstrate film comprises an adhesive, a transparent plastic, a glass, adichroic coating, a scattering material, a reflective polarizer, anabsorbing polarizer, a multilayer optical film, a retarder, a reflector,a retro reflector, a microstructured material, a lenticular structuredmaterial, a fresnel structured material, an absorber, or a combinationthereof.
 17. The optical component array of claim 11, wherein thesubstrate film comprises a film laminate.
 18. The optical componentarray of claim 17, wherein the film laminate comprises at least twofilms selected from a multilayer dielectric film including inorganicfilms and coatings or multilayer film stacks; organic films such aspolymeric films, polymeric film laminates, and multilayer polymericfilms including polarizers such as reflective polarizers and absorbingpolarizers; polarizers including polymeric multilayer optical filmpolarizers, McNeill polarizers, and wire-grid polarizers; retardersincluding quarter-wave retarders and half-wave retarders; and films orcoatings such as organic or inorganic dichroic reflectors and absorbers.19. The optical component array of claim 11, wherein the substrate filmcomprises a perimeter, and further comprising: a first frame disposedadjacent the perimeter of the major surface of the substrate film, asecond frame disposed adjacent the perimeter of the opposing majorsurface of the substrate film, and registration features disposed andaligned within each of the first frame and the second frame.
 20. Apolarizing beamsplitter (PBS) array, comprising: a reflective polarizer;a plurality of first machined prisms spaced apart by substantially flatfirst land regions parallel to the reflective polarizer, each firstmachined prism having a first diagonal surface adhered to a majorsurface of the reflective polarizer; and a plurality of second machinedprisms spaced apart by substantially flat second land regions parallelto the reflective polarizer, each second machined prism having a seconddiagonal surface adhered to an opposing major surface of the reflectivepolarizer, wherein each of the plurality of the first and the secondmachined prisms are aligned in registration with one another, forming aPBS array contiguous with the reflective polarizer.
 21. The PBS array ofclaim 20, wherein the plurality of first machined prisms and theplurality of second machined prisms each form a rectangular shapedarray.
 22. The PBS array of claim 20, wherein the machined prisms arepolished using a technique comprising mechanical polishing, flamepolishing, vapor polishing, or a combination thereof.
 23. The PBS arrayof claim 20, wherein the first machined prisms and the second machinedprisms each comprise a low-birefringent material.
 24. The PBS array ofclaim 23, wherein the low-birefringent material comprises an acrylicpolymer, a polycarbonate polymer, a cyclo-olefin copolymer, or a glass.25. The PBS array of claim 24, wherein the acrylic polymer is a castacrylic polymer.
 26. The PBS array of claim 20, wherein the reflectivepolarizer comprises a polymeric multilayer optical film polarizer, aMcNeill polarizer, or a wire-grid polarizer.
 27. The PBS array of claim20, wherein the reflective polarizer comprises a perimeter, and furthercomprising: a first frame disposed adjacent the perimeter of the majorsurface of the reflective polarizer, a second frame disposed adjacentthe perimeter of the opposing major surface of the reflective polarizer,and registration features disposed and aligned within each of the firstframe and the second frame.
 28. A method of making an optical componentarray, comprising: machining at least two first grooves into a firstsheet opposite a first planar surface, such that a substantially flatfirst land region parallel to the first planar surface separates eachfirst groove from the first planar surface; machining at least twosecond grooves into a second sheet opposite a second planar surface,such that a substantially flat second land region parallel to the secondplanar surface separates each second groove from the second planarsurface; positioning a substrate film between the first planar surfaceand the second planar surface; aligning in registration the at least twofirst grooves with the at least two second grooves; and adhering thesubstrate film between the first planar surface and the second planarsurface.
 29. The method of claim 28, further comprising machiningcrosscuts into at least one of the first and second sheets at an angleto the at least two first grooves and the at least two second grooves.30. The method of claim 29, wherein the crosscuts are perpendicular tothe at least two first grooves and the at least two second grooves. 31.A method of making a PBS array, comprising: machining a first pluralityof parallel vee-shaped ridges into a first sheet opposite a first planarsurface, such that adjacent vee-shaped ridges are separated by asubstantially flat first land region parallel to the first planarsurface; machining a second plurality of parallel vee-shaped ridges intoa second sheet opposite a second planar surface, such that adjacentvee-shaped ridges are separated by a substantially flat second landregion parallel to the second planar surface; positioning a substratefilm between the first planar surface and the second planar surface;aligning in registration the first plurality of parallel vee-shapedridges with the second plurality of parallel vee-shaped ridges; andadhering the substrate film between the first planar surface and thesecond planar surface.
 32. The method of claim 31, wherein machiningcomprises milling and fly-cutting.
 33. The method of claim 31, whereinthe substrate film comprises an adhesive, a transparent plastic, aglass, a dichroic coating, a scattering material, a reflectivepolarizer, an absorbing polarizer, a multilayer optical film, aretarder, a reflector, a retro reflector, a microstructured material, alenticular structured material, a fresnel structured material, anabsorber, or a combination thereof.
 34. The method of claim 31, furthercomprising singulating the optical component array by severing substratefilm, the first land region, and the second land region by lasercutting, sawing, milling, fly-cutting, or a combination thereof.
 35. Themethod of claim 31, further comprising machining crosscuts into at leastone of the first and second sheets at an angle to the first plurality ofparallel vee-shaped ridges and the second plurality of parallelvee-shaped ridges.
 36. The method of claim 35, wherein the crosscuts areperpendicular to the first plurality of parallel vee-shaped ridges andthe second plurality of parallel vee-shaped ridges.